Panel and a method for producing the panel

ABSTRACT

A panel (1) comprising a front surface (2) shaped to simulate a framed-up panel is manufactured by forming a main panel member (4) from a main substrate (7) laminated with a main veneer sheet (10). A front surface (5) of the main panel member (4) is formed and shaped to simulate a pair of stiles (12) and an infill panel (14) and to define rail receiving surfaces (15) at opposite ends of the infill panel (14). Rails (16) each formed from a secondary substrate (20) laminated with a secondary veneer sheet (24) are bonded to the rail receiving surfaces (15) and join the stiles (12).

The present invention relates to a panel and to a method for producingthe panel having first and second opposite major surfaces, the firstmajor surface simulating a framed-up panel of the type comprising aninfill panel and a pair of spaced apart stiles joined by a pair ofspaced apart rails which together extend around the infill panel.

Wood panels of the type which are referred to as framed-up panels areused extensively, for example, as apartment doors, doors for cabinets,cupboards, panels for coffins, panelling for walls, ceilings and thelike. In general, such panels comprise a frame formed by spaced apartvertical stiles joined by spaced apart horizontal rails which togethersurround an infill panel or a plurality of infill panels. Traditionally,the stiles, rails and infill panel have been constructed separately fromhardwood, such as for example, mahogany, oak and the like and thenassembled. However, due to the relatively high cost of such woods, suchpanels are commonly constructed wholly or partly from a substrate of lowgrade wood, wood particles or chips laminated with a veneer sheet. Forexample, the infill panel may comprise a substrate of a low grade wood,for example chipboard, fibre board of high, medium or low density, orother suitable substrate laminated with a veneer sheet of hardwood,softwood, synthetic foil or the like. The stiles and rails may likewisebe constructed from a similar or different type of substrate laminatedwith a similar or different veneer sheet, or may be of hardwood. Whilesuch framed-up panels result in a reduction in the material cost,nonetheless the labour cost required in assembling such panels isrelatively high.

It is known to produce a framed-up panel using a single sheet of lowgrade wood as a substrate laminated with a veneer sheet of hardwood,softwood or synthetic foil. Typically the substrate is formed from asheet of chipboard, medium density fibre board or the like. One surfaceof the substrate is machined to form simulated stiles, rails and aninfill panel. If desired the infill panel may simulate a raised infillpanel. A single veneer sheet is laminated to the formed surface bycompression moulding the veneer sheet to substrate to follow thecontours of the formed surface. Alternatively, in cases where the depthof the surface of the infill panel below the surface of the stiles andrails is relatively shallow, the stiles, rails and infill panel may beformed by embossing during lamination of the veneer sheet to thesubstrate. In such cases, machining of the substrate prior to laminationwith the veneer sheet is avoided. Framed-up panels formed in this wayhave been of only limited success, irrespective of whether a surface ofthe substrate has been machined to form the stiles, rails and infillpanel prior to lamination of the veneer sheet, or not. Such panelssuffer from two major disadvantages. Firstly, where the veneer sheet isof timber or other sheet material having a grain pattern, since a singleveneer sheet is laminated to the substrate, the grain of the veneersheet runs in a single direction only over the entire panel.Accordingly, where the grain runs parallel to the stiles, the grain mustrun transversely of the rails or vice versa. This is clearlyundesirable, since the panel so formed lacks a look of authenticity. Asecond major disadvantage of such panels is that the maximum depthbetween the surface of the infill panel and the surface of the stilesand rails is limited. Wood veneer sheets while they are relativelymalleable and stretchable in one direction, namely, in a directiontransversely of the grain, their malleability and stretchability isrelatively poor in a direction parallel to the grain. This seriouslylimits the depth to which the surface of the infill panel can be formedrelative to the surface of the stiles and rails. Where the grain of thewood veneer runs transversely across the rails, if the depth of thesurface of the infill panel below the surface of the rails is too great,in other words, if the steps between the surface of the infill panel andthe surface of the rails are too great, the veneer sheet ruptures onbeing bent transversely across the grain to accommodate the stepsbetween the infill panel and the respective rails. This is aparticularly serious problem where the side edge profile of the railsadjacent the infill panel is relatively sharp and forms a relativelyshape angle and a deep step between the infill panel surface and thesurface of the rails. Accordingly, as well as limiting the depth betweenthe surface of the infill panel and the surface of the rails or stilesas the case may be, the side edge profile of the rails and stiles whichcan be accommodated in such panels is limited.

A method for producing a framed-up panel which attempts to overcomethese problems is disclosed in European Patent Specification No.0,277,775A. The panel is formed from a single substrate of low gradewood, typically, chipboard. One surface of the substrate is machined toform a pair of spaced apart stiles joined by rails which surround aninfill panel. The substrate is laminated with a number of separateveneer sheets. One veneer sheet is laminated to the portion of thesubstrate defining the infill panel. Separate veneer sheets arelaminated to the portions of the substrate defining the stiles, whilefurther separate veneer sheets are laminated to the portions of thesubstrate defining the rails. In this way, it is possible to arrange thegrain of the veneer sheets to extend parallel to the rails and stiles.Furthermore, this method of constructing a panel also facilitates agreater depth of the surface of the infill panel relative to the surfaceof the rails and stiles. A disadvantage of this method for forming apanel is that a relatively high degree of precision is required to shapeand position the veneer sheets on the substrate, and this tends toresult in a panel of relatively high cost, and with a limited field ofuse.

An alternative method for constructing a framed-up panel which alsoattempts to overcome the problems of known methods is disclosed inGerman Patent Specification No. 34 23 252. The panel comprises asubstrate of chipboard which is laminated with a first veneer sheetwhich covers the entire surface of the substrate which is to simulatethe framed-up panel surface. The grain of the veneer sheet runs parallelto the stiles. Two transverse veneer sheets are laminated on top of thefirst veneer sheet at opposite ends of the panel and are located inpositions where rails are to be formed. The grain of the transverseveneer sheets runs parallel to the respective rails. The veneer sheetsand the substrate are laminated together, and the simulated stiles,rails and infill panel are formed by embossing during lamination. Themethod for forming a panel disclosed in this German Specification whileit enables a panel to be formed with the grain of the veneer sheetsrunning parallel to the respective stiles and rails, it does notfacilitate the formation of a framed-up panel with a relatively deepstep between the infill panel surface and the surface of the stiles andrails. Furthermore, because of the need to position and orient a numberof veneer sheets on the substrate prior to lamination thereof, theproduction of panels using this method tends to be relatively tediousand time consuming, thus leading to a relatively high cost panel, whichalso has a limited field of use.

There is therefore a need for a panel with at least one surface whichsimulates a framed-up panel and a method for producing such a panelwhich overcomes the problems of known panels and methods.

It is an object of the invention to provide a method for producing apanel having at least one major surface which simulates a framed-uppanel and which overcomes the problems of known methods. It is also anobject of the invention to provide such a panel. In particular, it is anobject of the invention to provide a method for producing a panel havingat least one major surface which simulates a framed-up panel from asubstrate and a veneer sheet, whereby the method accommodates theformation of a panel with a reasonable depth between the surface of thestiles and rails on the one hand and the surface of the infill paneladjacent the stiles and rails on the other hand without the danger ofrupturing of the veneer sheet adjacent a profiled step or edge surfacebetween the infill panel and the stiles and rails. Further, it is anobject of the invention to provide a method for producing such a panelin which a grain pattern on the stiles and rails runs parallel to therespective stiles and rails. A further object of the invention is toprovide a panel produced according to the method.

The invention overcomes the problems of known methods for producing apanel by virtue of the fact that in accordance with the invention thereis provided a method for producing a panel having first and secondopposite major surfaces, the first major surface simulating a framed-uppanel of the type comprising an infill panel and a pair of spaced apartstiles joined by a pair of spaced apart rails which together extendaround the infill panel, wherein the method comprises the steps ofproviding a main panel member having first and second opposite majorsurfaces corresponding respectively to the first and second surfaces ofthe panel, the main panel member being formed from a main substratehaving first and second opposite major faces, and a main veneer sheetlaminated to the first face of the main substrate for forming the firstsurface of the main panel member, shaping the first surface of the mainpanel member to simulate two spaced apart elongated stiles and an infillpanel extending between the stiles and to define two spaced apart railreceiving surfaces extending between the stiles adjacent respectiveopposite ends of the infill panel, and securing two spaced apartelongated rails to the respective rail receiving surfaces, the railsextending between and joining the stiles.

The advantages of the invention are many. The method of the inventionfacilitates the production of a panel in which at least one majorsurface of the panel simulates a framed-up panel having stiles, railsand an infill panel. The method of the invention provides twoparticularly important advantages in that, firstly, the panel may beformed with a reasonable depth between the surface of the stiles andrails and the surface of the infill panel adjacent the stiles and rails,and secondly, the panel may be formed with the grain pattern on thestiles and rails running substantially parallel to the respective stilesand rails. These advantages are achieved by virtue of the fact that themethod requires the provision of a main panel member which is formed tosimulate the infill panel and stiles only, and the rails are thensubsequently secured to the main panel member. Because of this, therails may be produced from solid timber or from a substrate laminatedwith a veneer sheet, and in both cases the rails can be provided withthe grain pattern of the rails running parallel to the respective rails.Additionally, where each rail comprises a secondary substrate and asecondary veneer sheet, the secondary veneer sheet can be arranged onthe substrate so that its direction of malleability and stretchabilityextends transversely of the rail to facilitate bending of the secondaryveneer sheet over and along a side edge surface of the rail adjacent theinfill panel.

By virtue of the fact that the main panel member is formed without therails, in other words, by virtue of the fact that the main panel memberis formed with the stiles and infill panels only, the main veneer sheetcan be arranged on the main substrate so that its direction ofmalleability and stretchability is such as to facilitate bending andforming of the main veneer sheet over and along side edge surfaces ofthe stiles adjacent the infill panel.

A further advantage of the invention is that by virtue of the fact thatthe main panel member comprises a main substrate and a main veneer sheetthe main panel member, and in turn the panel can be formed readilyquickly and easily at relatively low cost of production.

Preferably, the first surface of the main panel member is shaped byforming an elongated trough shaped recess in the first surface extendinglongitudinally from end to end of the main panel member, the recessdefining a base which forms the infill panel and the rail receivingsurfaces, and the recess defining opposite side walls extending from thebase which form respective side edge surfaces of the stiles. By formingthe panel in this fashion all the above discussed advantages of theinvention are achieved, and in particular, a particularly low cost,economical, simple and easy to preform method is provided.

In one embodiment of the invention portion of the base of the recess israised or lowered to form an infill panel of corresponding shape. Theadvantage of this feature of the invention is that it permits formationof an infill panel of any desired shape.

In one embodiment of the invention the main veneer sheet has alongitudinally extending grain pattern, and the main veneer sheet islaminated to the main substrate with the grain pattern extendingparallel to the stiles. Where the main veneer sheet is of wood, byvirtue of the fact that the grain pattern extends parallel to the stilesthe main veneer sheet is malleable and stretchable in a directiontransverse of the stiles, and accordingly, bending of the main veneersheet between the respective stiles and the infill panel isaccommodated. Furthermore, the panel has an authentic look.

In another embodiment of the invention each rail has first and secondopposite major surfaces, the first surface corresponding to the firstsurface of the panel, and the second surface being secured to thecorresponding rail receiving surface of the main panel member, themethod further comprising the steps of forming each rail by providing asecondary substrate having first and second opposite major faces, andlaminating a secondary veneer sheet to the first face of the secondarysubstrate for forming the first surface of the rail. The advantage ofthis feature of the invention is that it permits a panel of relativelylow cost to be produced, since the rail can largely be provided from arelatively low grade timber or from timber waste.

Preferably, the secondary veneer sheet of each rail has a longitudinallyextending grain pattern, the secondary veneer sheets being laminated tothe respective secondary substrates with the grain pattern extendingsubstantially parallel to the respective rails. The advantage of thisfeature of the invention is that where the secondary veneer sheet is ofwood, the secondary veneer sheet is arranged with its direction ofmalleability and stretchability extending transversely of each rail, andaccordingly, the secondary veneer sheet may be bent over and along aside edge of the rail adjacent the infill panel without danger ofrupturing the secondary veneer sheet. Additionally, because the grain ofthe secondary veneer sheet extends longitudinally of the rail the panelso formed has a look of authenticity.

In one embodiment of the invention a longitudinally extending side edgesurface of each rail adjacent the infill panel is shaped to form atransverse profile, which extends longitudinally along the rail.Preferably, the secondary veneer sheet of each rail extends over theside edge surface of the rail to facilitate ease of forming of the rail.

In one embodiment of the invention a side edge surface of each secondarysubstrate is shaped with a side edge surface profile which roughly formsan outline of the side edge surface profile of the rail, and thesecondary veneer sheet is laminated to the secondary substrate after theside edge surface profile has been formed in the secondary substrate.This provides a relatively inexpensive method for producing the panel,and also facilitates a panel to be produced with a reasonable depthbetween the surface of the stiles and rails and the infill panel surfaceadjacent the stiles and rails.

In one embodiment of the invention the side edge surface profile of eachrail is formed during lamination of the secondary veneer sheet to thesecondary substrate. This provides relatively low cost and inexpensivemethod for producing the panel.

Preferably, the secondary veneer sheet of each rail is laminated to thesecondary substrate by compression moulding. Advantageously, eachsecondary substrate is a one piece substrate formed from a single pieceof material. Preferably, the secondary veneer sheet of each rail isformed from a single veneer sheet.

In one embodiment of the invention the main substrate is a one piecesubstrate formed from a single sheet of material. The advantage ofproviding the main substrate as a one piece substrate formed from asingle sheet of material is that it provides a relatively strong panel,and also provides a relatively inexpensive method for producing thepanel.

Advantageously, the first face of the main substrate is shaped to form arough outline of the first surface of the main panel member. Theadvantage of this feature of the invention is that it provides arelatively inexpensive method for producing the panel, and itfacilitates the provision of a panel with a reasonable depth between thesurface of the stiles and rails and the surface of the infill paneladjacent the stiles and rails.

Preferably, the first face of the main substrate is shaped by machining.This is a particularly advantageous method of producing the main panelmember.

In one embodiment of the invention the main veneer sheet is laminated tothe main substrate after the first face of the main substrate has beenshaped.

In another embodiment of the invention the first surface of the mainpanel member is formed during lamination of the main veneer sheet withthe main substrate. Preferably, the main veneer sheet is laminated tothe main substrate by compression moulding.

In one embodiment of the invention the first surface of the main panelmember defines an intermediate stile receiving surface between thestiles and spaced apart therefrom for receiving an intermediate stilelocated intermediate and spaced apart from the stiles and extendingbetween and joining the rails, the intermediate stile being secured tothe stile receiving surface, respective infill panels being formedbetween the intermediate stile receiving surface and the respectiveadjacent stiles. The advantage of this aspect of the invention is thatit enables a panel to be produced which is particularly suitable forforming an apartment door.

In another embodiment of the invention the first surface of the mainpanel member defines an intermediate rail receiving surface between therail receiving surfaces and spaced apart therefrom for receiving anintermediate rail located intermediate and spaced apart from the railsextending between and joining the stiles, the intermediate rail beingsecured to the intermediate rail receiving surface, respective infillpanels being formed between the intermediate rail receiving surface andthe respective adjacent rail receiving surfaces. The advantage of thisaspect of the invention is that it enables a panel member to be producedwhich is particularly suitable for forming an apartment door.

In another embodiment of the invention the side edge surface of eachstile adjacent the infill panel is shaped to form a transverse profile,which extends longitudinally along the side edge surface.

In a further embodiment of the invention the profile of the side edgesurfaces of the respective stiles and rails may be selected from any oneor more of the following profiles, bevelled, curved, convex and concave.

In one embodiment of the invention respective ends of each rail areshaped to accommodate the side edge profile of the adjacent stiles priorto securing the rails to the main panel member.

In another embodiment of the invention the main veneer sheet covers theentire first face of the main substrate. The advantage of this featureof the invention is that it provides relatively low cost and inexpensivemethod for producing the main panel member and in turn the panel.

Advantageously, the main veneer sheet is formed from a single sheet ofveneer.

In one embodiment of the invention each rail receiving surface isco-planar with an adjacent portion of the infill panel surface. Theadvantage of this feature of the invention is that it facilitatesproduction of the panel member.

In one embodiment of the invention each rail is secured to the mainpanel member so that the secondary veneer sheet merges with the mainveneer sheet to form the first surface of the panel. The advantage ofthis feature of the invention is that it provides an aestheticallypleasing panel.

Preferably, each rail is secured to the main panel member by bonding.

In one embodiment of the invention the main and secondary substrates maybe of similar or different materials, and may be selected from any oneor more of the following materials:

any suitable wood or reconstituted wood,

softwood,

hardwood,

chipboard,

oriented strand board,

high density, medium or low density fibre board, and

any composite material.

In another embodiment of the invention the main and secondary veneersheets may be similar or different and may be matched or otherwise, andmay be selected from any one or more of the following types of veneersheets:

timber veneer sheet of hardwood or softwood,

synthetic foil,

veneer sheet of plastics material which may or may not simulate a grain,

decorative veneer sheet, and

any other suitable veneer sheet.

In a further embodiment of the invention a backing veneer sheet islaminated to the second face of the main substrate to form the secondsurface of the panel.

In a still further embodiment of the invention the panel defines aperipheral side edge surface extending around the periphery of the paneljoining the first and second surfaces, and an edging strip is laminatedto the peripheral side edge surface.

Additionally the invention provides a panel having first and secondopposite major surfaces, the first major surface simulating a framed-uppanel of the type comprising an infill panel and a pair of spaced apartstiles joined by a pair of spaced apart rails which together extendround the infill panel, wherein the panel is formed using the methodaccording to the invention.

Further the invention provides a panel having first and second oppositemajor surfaces, the first major surface simulating a framed-up panel ofthe type comprising an infill panel and a pair of spaced apart stilesjoined by a pair of spaced apart rails which together extend around theinfill panel, wherein the panel comprises a main panel member havingfirst and second opposite major surfaces corresponding respectively tothe first and second surfaces of the panel, the main panel member beingformed from a main substrate having first and second opposite majorfaces, and a main veneer sheet laminated to the first face of the mainsubstrate for forming the first surface of the main panel member, thefirst surface of the main panel member being shaped to simulate twospaced apart elongated stiles and an infill panel extending between thestiles and to define two spaced apart rail receiving surfaces extendingbetween the stiles adjacent respective opposite ends of the infillpanel, and two spaced apart elongated rails secured to the respectiverail receiving surfaces, the rails extending between and joining thestiles.

Preferably, the first surface of the main panel member is shaped by theformation of an elongated trough shaped recess in the first surfaceextending longitudinally from end to end of the main panel member, therecess defining a base which forms the infill panel and the railreceiving surfaces, and the recess defining opposite side wallsextending from the base which form respective side edge surfaces of thestiles.

In one embodiment of the invention portion of the base of the recess israised or lowered to form an infill panel of corresponding shape.

In another embodiment of the invention the main veneer sheet is providedwith a longitudinally extending grain pattern which extendssubstantially parallel to the stiles. Advantageously, each rail hasfirst and second opposite major surfaces, the first major surfacecorresponding to the first surface of the panel, the second majorsurface being secured to the corresponding rail receiving surface of themain panel member, each rail comprising a secondary substrate havingfirst and second opposite major faces corresponding to the first andsecond surfaces of the rail, and a secondary veneer sheet laminated tothe first face of the secondary substrate for forming the first surfaceof the rail.

In one embodiment of the invention the secondary veneer sheet of eachrail is provided with a longitudinally extending grain pattern, whichextends substantially parallel to the rail.

In another embodiment of the invention a longitudinally extending sideedge surface of each rail adjacent the infill panel is shaped to form atransverse profile which extends longitudinally along the rail.

Preferably, the secondary substrate of each rail is a one piecesubstrate formed from a single piece of material.

Advantageously, the secondary veneer sheet of each rail is formed from asingle sheet of veneer.

Preferably, the rail is bonded to the main panel member.

In another embodiment of the invention the side edge surface of eachstile adjacent the infill panel is shaped to form a transverse profile,which extends longitudinally along the side edge surface.

A further advantage of the invention is that the production of simulatedframed-up panels using the method according to the invention isrelatively simple and economical. Accordingly, simulated framed-uppanels can be produced by mass production techniques relatively simplyand economically. Furthermore, such panels which comprise a plurality ofinfill panels may be provided at relatively low cost. Typical uses forsuch panels are apartment doors, panels for lining walls, ceilings andthe like. The method for producing the panels according to the inventionis particularly suitable for extrusion, or direct moulding from chips,fibres, or the like, and where such panels are provided with co-planarinfill panels, the main panel member may be formed by extrusion, and acontinuous extrusion may be formed which would be cut to length to forma plurality of main panel members. Additionally, the main panel membermay be readily easily sanded prior to securing the rails thereto and therails may also be readily easily sanded prior to securing to the mainpanel member.

The invention will be more clearly understood from the followingdescription of some preferred embodiments thereof given by way ofexample only with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a panel according to the invention,

FIG. 2 is an exploded perspective view of the panel of FIG. 1,

FIG. 3 is a cross-sectional end elevational view of the panel of FIG. 1on the line III--III of FIG. 1,

FIG. 4 is a cross-sectional end elevational view of the panel of FIG. 1on the line IV--IV of FIG. 1,

FIG. 5 is a cross-sectional side elevational view of the panel of FIG. 1on the line V--V of FIG. 1,

FIG. 6 is a perspective view of a panel according to another embodimentof the invention,

FIG. 7 is a plan view of portion of the panel of FIG. 6,

FIG. 8 is a plan view similar to FIG. 7 of the panel of FIG. 6 underconstruction,

FIG. 9 is a plan view of the panel of FIG. 6,

FIG. 10 is a cross-sectional end view of portion of the panel of FIG. 6on the line X--X of FIG. 8,

FIG. 11 is a cross-sectional side view of the portion of FIG. 10 on theline XI--XI of FIG. 8,

FIG. 12 is a cross-sectional end view of another portion of the panel ofFIG. 6 on the line XII--XII of FIG. 8,

FIG. 13 is a cross-sectional side view of the portion of FIG. 12 on theline XIII--XIII of FIG. 8, and

FIG. 14 is a cross-sectional end view of another portion of the panel ofFIG. 6 on the line XIV--XIV of FIG. 9.

Referring to the drawings, and initially to FIGS. 1 to 5 thereof, thereis illustrated a panel according to the invention indicated generally bythe reference numeral 1 of wood. The panel 1 has a first major surfaceand a second opposite major surface which for convenience arehereinafter referred to as a front surface 2 and a rear surface 3,respectively. The front surface 2 is formed and shaped to simulate aframed-up panel, and the rear surface 3 is planar. The framed-up panel 1is suitable typically as a door for a cabinet or cupboard, or as a panelfor a coffin, wall, ceiling or the like. The panel 1 is formed from amain panel member 4 having front and rear surfaces 5 and 6,respectively, corresponding to the front and rear surfaces 2 and 3,respectively, of the panel 1. The main panel member 4 comprises a mainsubstrate 7 having front and rear faces 8 and 9 and a main veneer sheet10 laminated to the front face 8 of the main substrate 7 to form thefront surface 5 of the main panel member 4. The front surface 5 of themain panel 4 is shaped by forming an elongated trough shaped recess 11in the front surface 5 extending longitudinally from end to end of themain panel member 4 to form on the front surface 5 two spaced apartstiles 12. The recess 11 defines a base 13 which forms an infill panel14 extending between the stiles 12 and two rail receiving surfaces 15extending between the stiles at opposite ends of the infill panel 14 forreceiving a pair of spaced apart rails 16 which extend between and jointhe stiles 12. Opposite side walls 17 of the recess 11 extend from thebase 13 and form longitudinally extending side edge surfaces 28 of therespective stiles 12. Each rail 16 has first and second opposite majorsurfaces which for convenience are hereinafter referred to as outer andinner surfaces 18 and 19, respectively. Each rail 16 comprises asecondary substrate 20 having a first face 21 and a second face 22. Asecondary veneer sheet 24 is laminated to the first face 21 of thesecondary substrate 20 of each rail 16 to form the outer surface 18. Theinfill panel 14 is a raised infill panel and defines a raised centralsurface 25 and a lower surface 26 extending around the periphery of thecentral surface 25 adjacent the stiles 12 and rails 16. The lowersurface 26 is co-planar with the rail receiving surfaces 15. A profiledstep 27 extends around the periphery of the raised central surface 25between the central surface 25 and the lower surface 26. The side edgesurface 28 of each stile 12 adjacent the infill panel 14 is shaped toform a transverse convex curved profile which extends longitudinallyalong each stile 12 and joins a front surface 29 of the stile 12 to thelower surface 26 of the infill panel 14. A longitudinally extending sideedge surface 30 extends along each rail 16 adjacent the infill panel 14and is shaped to form a transverse convex curved profile which extendslongitudinally along each rail 14 and joins the outer surface 18 of therail 16 to the lower surface 26 of the infill panel 14.

The main substrate 7 and the secondary substrates 20 are of chipboardmaterial, and the main veneer sheet 10 and secondary veneer sheets 24are of a hardwood material, typically oak or mahogany and are generallymatched prior to laminating to the respective main and secondarysubstrates 7 and 20, respectively. The main veneer sheet 10 is laminatedto the main substrate 7 so that the grain pattern 31 of the main veneersheet 10 runs substantially parallel to the stiles 12. The secondaryveneer sheets 24 are laminated to the respective secondary substrates 20so that the grain pattern 32 of the secondary veneer sheets 24 runssubstantially parallel to the rails 16. A backing veneer sheet 33 of anysuitable veneer material, timber or foil is laminated to the rear face 9of the main substrate 7 to form the planar rear surface 3 of thepanel 1. An edging strip 34 of foil is laminated to and extends aroundthe peripheral side edge surface 35 of the panel 1.

A method according to the invention for producing the panel 1 will nowbe described. A sheet of chipboard material is cut to size to form themain substrate 7 of the main panel member 4. The front face 8 of themain substrate 7 is shaped by machining using a routing tool to form arough outline of the recess 11 for forming the stiles 12 and the infillpanel 14 as well as the rail receiving surfaces 15. Provided thematerial of the main substrate 7 is a relatively yielding type material,it is not essential that the front face 8 of the main substrate 7 shouldbe machined to closely and accurately define the shape of the stiles 12,infill panel 14 and the rail receiving surfaces 15 of the front surface5 of the main panel member 4. On the front face 8 of the main substrate7 having been shaped, the main veneer sheet 10 is laminated to the frontface 8 of the main substrate 7 using a compression moulding andlaminating process. The main substrate 7 or the main veneer sheet 10 iscoated with a suitable adhesive which may be a liquid or film typeadhesive, and the main substrate 7 with the main veneer sheet 10 placedover the front face 8 is placed in a compression moulding press. Amoulding die defining the shape of the front surface 5 of the main panelmember 4 is brought into engagement with the main veneer sheet 10 toform the final shape of the front surface 5 of the main panel member 4.Appropriate pressure is applied to the die for bonding the main veneersheet 10 to the main substrate 7 and for moulding the main veneer sheet10 into the desired shape to form the front surface 5 of the main panelmember 4. The die and base of the compression moulding press aregenerally heated. The temperature and pressure to which the mainsubstrate 7 and the main veneer sheet 10 are subjected during laminationare a function of the adhesive used, and may also be a function of thesubstrate and veneer sheet. Typically the temperature and pressure are50° C. to 150° C. and 4 bar to 10 bar, respectively. The backing veneersheet 33 is then laminated to the rear face 9 of the main substrate 7 ormay be laminated to the main substrate 7 during lamination of the mainveneer sheet 10 as desired using a similar laminating process.

The rails 16 are each cut from an elongated rail which is prior formed.An elongated batten of chipboard of length sufficient to form many rails16 and which forms the secondary substrates 20 of the rails 16 is firstshaped by machining to provide the first face 21 and the second planarface 22. A side edge surface which corresponds to the side edge surface30 of each rail 16 adjacent the infill panel 14 is machined to form arough outline of the side edge profile surface 30 of each rail 16. Anelongated secondary veneer sheet of length sufficient to form many rails16 is laminated to the secondary substrate 20 in similar fashion as themain veneer sheet 10 is laminated to the main substrate 7. The secondaryveneer sheet 24 extends over the entire first face 21 and the side edgesurface of the secondary substrate 20 which corresponds to the side edgesurface 30 of the rail 16. The final desired shape of the outer surface18 and the side edge profile surface 30 of the rails 16 is formed duringlamination by, for example, compression moulding. The rails 16 of thedesired length are then cut from the laminate of secondary substrate 20and secondary veneer sheet 24. Ends 37 of each rail 16 are shaped toaccommodate the side edge profile surfaces 28 of the respective stiles12. The shaping of the ends 37 is typically carried out by machining.The rail receiving surfaces 15 and side edge surfaces 29 of the stiles12 adjacent the rail receiving surfaces 15 are coated with an adhesive.The rails 16 are placed on the adhesive coating with the inner surface19 of the respective rails 16 engaging the adhesive. The shaped ends 37of the rails 16 engage the adhesive coating on the side edge surfaces 29of the stiles 12. The assembled main panel member 4 with the rails 16 inplace, is placed in a suitable press and pressure is applied to therails 16 for bonding the rails 16 to the main panel member 4. In thisway the second face 22 of the secondary substrates 20 of the rails 16are bonded directly to the main veneer sheet 10 of the main panel member4. A typical pressure applied by the press for bonding the rails 16 tothe main panel member 4 is of the order of 5 bar to 10 bar. Suitableadhesives for bonding the rails 16 to the main panel member 4 arepolyvinyl acetate adhesive, urea formaldehyde adhesives and the like.The edging strip 34 is bonded to the peripheral side edge surface 35using conventional bonding methods.

It has been found that by producing a panel using the method accordingto the invention, depths a between the front surface 5 of the infillpanel 14, adjacent the stiles 12 and rails 16, namely, the lower surface26 of the infill panel 14, and the front surface 5 of the stiles 12 andthe outer surface 18 of the rails 16 of up to 18 mm can be achieved. Themethod is particularly suitable for producing panels in which the deptha between the lower surface 26 of the infill panel 14 and the frontsurface 5 of the stiles and the outer surface 18 of the rails 16 is inthe range of 5 mm to 18 mm, and in particular, where the depth a is inthe range of 10 mm to 12 mm. Indeed, in theory there is no limit to thedepth a between the lower surface 26 of the infill panel 14 and theco-planar surfaces 28 and 18 of the stiles 12 and rails 16,respectively. In general, it is envisaged that the depth a will be inthe range of 30% to 70% of the maximum thickness d of the main panelmember 4 from the front surface 5 to the rear surface 6 of the mainpanel 4 at the stiles 12. Accordingly, since in general, it is envisagedthat the rail receiving surfaces 15 will be co-planar with the lowersurface 26 of the infill panel 14, the thickness e of the rails 16including the secondary substrate 20 and the secondary veneer sheet 24will be in the order of 30% to 70% of the maximum thickness d of themain panel member 4. Needless to say, where the rail receiving surfaces15 are co-planar with the lower surface 26 of the infill panel 14, thethickness e of the rails 16 will be similar to the depth a between theouter surface of the rails 16 and the lower surface 26 of the infillpanel 14. For example, where the depth a is 10 mm the thickness e willlikewise be 10 mm.

Referring now to FIGS. 6 to 14 there is illustrated a panel 50 accordingto another embodiment of the invention which in this case is suitablefor forming one face of an apartment door. An apartment door would inpractice be formed from two such panels 50 which would be laminatedtogether to form respective front and rear faces of the apartment door,or may be laminated to a third intermediate panel of low grade timber orheat insulating material, or to an intermediate frame. The panel 50 ismanufactured according to a method similar to that described formanufacturing the panel 1, and furthermore, the panel 50 is somewhatsimilar to the panel 1 and similar components are identified by the samereference numerals. The main difference between the panel 50 and thepanel 1 is that four infill panels 14 are provided in the panel 50. Thepanel 50 comprises a main panel member 51 of similar construction to themain panel member 4 of the panel 1. The main panel member 51 has a frontsurface 52 corresponding to the front surface 2 of the panel 50 whichwould form one of the faces of the apartment door. The main panel member51 has a planar rear surface 53 corresponding to the rear surface 3 ofthe panel 50, which in practice is laminated to a corresponding surfaceof another panel 50 to form the other face of the apartment door. Thefront surface 52 of the main panel member 51 is shaped by forming therecess 11 which defines a pair of stiles 12 and forms four raised typeinfill panels 14. An intermediate rail receiving surface 60 is definedbetween adjacent infill panels 14 for receiving an intermediate rail 55,and two intermediate stile receiving surfaces 58 are defined betweenadjacent infill panels 14 for receiving intermediate stiles 57 as willbe described below. The intermediate rail receiving surface 60 and theintermediate stile receiving surfaces 58 are co-planar with the railreceiving surfaces 15 and the lower surfaces 26 of the infill panels 14.The main panel member 51 is formed and shaped by a similar method asthat used in forming and shaping as the main panel member 4 of the panel1 and comprises a main substrate 7 laminated with a main veneer sheet 10and a backing veneer sheet 33. Although in many cases where the rearsurfaces will not be exposed in use the backing veneer sheet 33 may beomitted.

Three spaced apart rails, namely, a top rail 54, and a bottom rail 56and the intermediate rail 55 which are of substantially similarconstruction to the rails 16 of the panel 1 are bonded to the railreceiving surfaces 15 and the intermediate rail receiving surface 60 ofthe main panel member 51 and extend between the stiles 12. Theintermediate stiles 57 extend longitudinally of the main panel member 51between and parallel to and spaced apart from the stiles 12 and join therails 54, 55 and 56. The intermediate stiles 57 are bonded to the stilereceiving surfaces 58 which are similar to the rail receiving surfaces15 and are co-planar with the rail receiving surfaces 15 and lowersurfaces 26 of the infill panels 14. The stiles 12, rails 54, 55 and 56and the intermediate stiles 57 extend around the infill panels 14.

The rails 54, 55 and 56 are formed in similar fashion as the rails 16 ofthe panel 1 and each comprises a secondary substrate 20 laminated with asecondary veneer sheet 24. The only difference being that theintermediate rail 56 is formed with a pair of side edge surface profiles30.

The intermediate stiles 57 are formed in substantially similar fashionas the rails 16 from a secondary substrate 20 laminated with a secondaryveneer sheet 24. Ends 59 of the rails 54, 55 and 56 and of theintermediate stiles 57 are shaped to accommodate adjacent side edgesurface profiles 29 and 30 of the stiles 12 and rails 54, 55 and 56,respectively, against which the ends 59 abutt.

The method for producing the panel 50 is as follows. The main panelmember 51 is provided by cutting a sheet of suitable material to size toform the main substrate 7. Typically, chipboard or other suitable lowcost timber or a board made from other waste wood material. A roughoutline of the recess 11 to form a rough outline of the front surface 52of the main panel member 51 is machined in the front face 8 of the mainsubstrate 7 so that the outline of the stiles 12, the infill panels 14and the rail and stile receiving surfaces is formed. The main veneersheet 10 of hardwood with the grain pattern 31 running parallel to thestiles 12 is then laminated to the front surface 8 of the main substrate7 in a compression moulding press where the main veneer sheet 10 isshaped and formed to form the front surface 52 of the main panel member51. After lamination of the main veneer sheet 10 to the main substrate 7or simultaneously therewith, the backing veneer sheet 33, should this berequired, is laminated to the rear face 9 of the main substrate 7. Therails 54, 55 and 56 and the intermediate stiles 57 are formed in similarfashion to the rails 16 of the panel 1 and are bonded to the respectiverail receiving surfaces 15 and the stile receiving surfaces 58 insimilar fashion as the rails 16 are bonded to the rail receiving surface15 of the main panel member 4 of the panel 1. The grain pattern of thesecondary veneer sheets 24 is arranged to run parallel to the rails 54and 56 and the intermediate rail 55 and stiles 57. Although notillustrated, the ends 59 of the intermediate stiles 57 are identical tothe ends 59 of the intermediate rail 55. A cross-sectional view of theintermediate stile 57 on the line XIII'--XIII' of FIG. 9 would besubstantially identical to the cross-sectional view of the intermediaterail 55 on the line XIII--XIII illustrated in FIG. 13. The edge veneerstrip 34 is laminated to the side edge surface 35 of the panel 50.

Should it be desired to form an apartment door from a single panel, themain panel member would be formed from a main substrate of sufficientthickness corresponding to the desired thickness of the apartment door.The front and rear surfaces 2 and 3 of the panel 50 would each be shapedin the form of framed-up panels. Thus, the main panel member 51 would beformed with identical front and rear surfaces 52 and 53 and main veneersheets 10 would be laminated to both the front and rear faces 8 and 9,respectively of the main substrate 7. Rails 54, 55 and 56 andintermediate stiles 57 would be laminated to the front and rear surfaces52 and 53 of the main panel member 51.

While the panels according to the invention have been described ashaving a front surface shaped to form a framed-up panel suitable for useas a door for a cupboard, an apartment door or the like, it will beappreciated that the panel according to the invention may be providedfor many other purposes.

It is envisaged that the rails need not extend perpendicularly to thestiles, but rather, may be at any angle or angles to the stiles.

It is also envisaged that the infill panel may be of other shape, andwhere the infill panel is provided with a raised surface having at leasttwo opposite edges curved, it is envisaged that the rails or stilesadjacent the curved edges of the raised surface of the infill panel maybe similarly shaped. Additionally, it is envisaged that the infill panelmay be of hexagonal, octagonal or other desired shapes, and in whichcase, the rails extending between the stiles would be appropriatelyformed and located. It is also envisaged that the rail or rails adjacentthe top of an infill panel may be arched or arranged to form an arch.

While in the case of the panel of FIGS. 1 to 5 the method for producingthe panel has been described for producing a single panel only, it isenvisaged that the method for producing the panel may be such as toenable a plurality of main substrates laminated with the main veneersheets to be formed for a plurality of panels from one continuous sheetof chipboard or other substrate material. In which case, where thecontinuous sheet of substrate has been machined and laminated thelaminated sheet would then be cut to form respective main panel membersfor respective panels.

Additionally, if desired the rails may be individually formed from ashort length of secondary substrate and secondary veneer sheet.

It will of course be appreciated that while the panels have beendescribed as being formed by main and secondary substrates of chipboard,substrates of any other material may be provided, for example, highdensity, medium density or low density fibre board, low grade wood,reconstituted wood, oriented strand board, composite material panels,plastics materials, heat insulation materials, metals or any otherdesired or suitable substrate material.

Indeed, in certain cases, it is envisaged that the main and/or secondaryveneer sheets may be of a plastics material, foils, or the like whichmay or may not simulate a wood finish, and may or may not be providedwith a grain. Needless to say, a veneer sheet of any other suitable ordesired material may be used. It is also envisaged that edging strips ofmaterial other than foil may be used, and indeed, in certain cases, itis envisaged that the edging strip may be a wood veneer, or indeed, maybe a strip of wood, or plastics material, or any other suitablematerial.

It is also envisaged that each rail may be formed from a solid batten ofhard or soft wood.

While in the method for laminating the veneer sheets to the substratesand for securing the rails to the main panel member, a press comprisinga die has been used, it is envisaged that a membrane press may be used,and needless to say, any other suitable press system may be used.

It is envisaged in many cases that the main veneer sheet may not extendfully over the rail and stile receiving surfaces beneath the rails,intermediate rail and intermediate stiles. In such cases the main veneersheet may terminate adjacent the side edge surface profile of therelevant rail or stile, or may extend just beneath the rail or stileadjacent the side edge surface profile. The secondary substrate of therails, intermediate rails or stiles would then be effectively laminateddirectly onto the main substrate.

While a rough outline of the stiles and infill panel has been describedas being formed in the main substrate by machining using a routing tool,outline of the stiles and infill panel may be formed in the mainsubstrate using any other suitable machining, or any other forming orshaping means, for example, moulding, extrusion, or the like. It is alsoenvisaged that in many cases it may not be necessary to form or machinea rough outline of the stiles and infill panel on the main substrate, inwhich case, the stiles and infill panel would be formed in the frontsurface of the main panel member by compression moulding duringlamination of the main veneer sheet to the main substrate. This would bepossible in cases where the main substrate is provided by a sheet ofmaterial of relatively low density, such as, for example, low densitychipboard, fibreboard and the like.

While the panel suitable for forming an apartment door has beendescribed as having four infill panels, panels with any number of infillpanels may be provided, and in certain cases, it is envisaged that anumber of parallel intermediate stiles may be provided intermediate thestiles, and it is also envisaged that a number of intermediate rails maybe provided intermediate the rails.

What is claimed is:
 1. A method for producing a panel (1,50) havingfirst and second opposite major surfaces (2,3), the first major surface(2) simulating a framed-up panel of the type comprising an infill panel(14) and a pair of spaced apart stiles (12) joined by a pair of spacedapart rails (16, 54, 56) which together extend around the infill panel(14), the method comprising the steps of providing a main panel member(4,51) having first and second opposite major surfaces (5, 6, 52, 53)corresponding respectively to the first and second surfaces (2, 3) ofthe panel (1), the main panel member (4, 51) being formed from a mainsubstrate (7) having first and second opposite major faces (8, 9), and amain veneer sheet (10) laminated to the first face (8) of the mainsubstrate (7) for forming the first surface (5,52) of the main panelmember (4,51), shaping the first surface (5,52) of the main panel member(4,51) to simulate the pair of spaced apart elongated stiles (12) andthe infill panel (14) extending between the stiles (12), characterizedin that the first surface is shaped to define two spaced apart railreceiving surfaces (15) extending between the stiles (12) adjacentrespective opposite ends of the infill panel (14), and two spaced apartelongated rails (16) are secured to the respective rail receivingsurfaces (15), the rails (16) extending between and joining the stiles(12).
 2. A method as claimed in claim 1 characterised in that the firstsurface (5,52) of the main panel member (4,51) is shaped by forming anelongated trough shaped recess (11) in the first surface (5,52)extending longitudinally from end to end of the main panel member(4,51), the recess (11) defining a base (13) which forms the infillpanel (14) and the rail receiving surfaces (15), and the recess (11)defining opposite side walls (17) extending from the base (13) whichform respective side edge surfaces (28) of the stiles (12).
 3. A methodas claimed in claim 2, characterised in that portion (25) of the base(13) of the recess (11) is raised or lowered to form an infill panel(14) of corresponding shape.
 4. A method as claimed in claim 1characterised in that the main veneer sheet (10) has a longitudinallyextending grain pattern (31), and the main veneer sheet (10) islaminated to the main substrate (7) with the grain pattern (31)extending parallel to the stiles (12).
 5. A method as claimed in claim 1characterised in that each rail (16) has first and second opposite majorsurfaces (18,19), the first surface (18) corresponding to the firstsurface (2) of the panel (1,50), and the second surface (19) beingsecured to the corresponding rail receiving surface (15) of the mainpanel member (4,51), the method further comprising the steps of formingeach rail (16) by providing a secondary substrate (20) having first andsecond opposite major faces (21,22), and laminating a secondary veneersheet (24) to the first face (21) of the secondary substrate (20) forforming the first surface (18) of the rail (16).
 6. A method as claimedin claim 5 characterised in that the secondary veneer sheet (24) of eachrail (16) has a longitudinally extending grain pattern (32), thesecondary veneer sheets (24) being laminated to the respective secondarysubstrates (20) with the grain pattern (32) extending substantiallyparallel to the respective rails (16).
 7. A method as claimed in claim 1characterised in that the main substrate (7) is a one piece substrateformed from a single sheet of material, and the first face (8) of themain substrate (7) is shaped to form a rough outline of the firstsurface (5,52) of the main panel member (4,51).
 8. A method as claimedin claim 7 characterised in that the main veneer sheet (10) is laminatedto the main substrate (7) after the first face (8) of the main substrate(7) has been shaped.
 9. A method as claimed in claim 1 characterised inthat the main veneer sheet (10) covers the entire first face (8) of themain substrate (7).
 10. A method as claimed in claim 1 characterised byforming the main veneer sheet (10) from a single sheet of veneer.
 11. Amethod as claimed in claim 1 characterised by forming each railreceiving surface (15) so as to be co-planar with an adjacent portion ofthe infill panel surface (26).
 12. A method as claimed in claim 1characterized by forming the main and secondary substrates (7,20) of oneof similar and different materials, and materials forming the main andsecondary substrates (7,20) selected from the group consisting ofa wood,a reconstituted wood, a softwood, a hardwood, a chipboard, an orientedstrand board, a high, medium or low density fibre board, and a compositematerial panel, and forming the main and secondary veneer sheets (10,28)of one of similar or different veneer materials said veneer materialsselected from the group consisting of:a hardwood timber veneer sheet, asoftwood timber veneer sheet, a synthetic foil, a plastic veneer sheetwithout a grain, a plastic veneer sheet with a grain, and a decorativeveneer sheet.
 13. A panel having first and second opposite majorsurfaces (2, 3), the first major surface (2) simulating a framed-uppanel of the type comprising an infill panel (14) and a pair of spacedapart stiles (12) joined by a pair of spaced apart rails (16) whichtogether extend around the infill panel (14), the panel (1, 50)comprising a main panel member (4, 51) having first and second oppositemajor surfaces (5, 6, 52, 53) corresponding respectively to the firstand second surfaces (2, 3) of the panel (1, 50), the main panel member(4, 51) being formed from a main substrate (7) having first and secondopposite major faces (8, 9), and a main veneer sheet (10) laminated tothe first face (8) of the main substrate (7) for forming the firstsurface (5, 52) of the main panel member (4,51), the first surface (8)of the main panel member being shaped to simulate the pair of spacedapart elongated stiles (12) and the infill panel (14) extending betweenthe stiles (12), characterised in that the first surface (8) is shapedto define two spaced apart rail receiving surfaces (15) extendingbetween the stiles (12) adjacent respective opposite ends of the infillpanel (14), and two spaced apart elongated rails (16) are secured to therespective rail receiving surfaces (15), the rails (16) extendingbetween and joining the stiles (12).
 14. A panel as claimed in claim 13characterised in that the first surface (5,52) of the main panel member(4,51) is shaped by the formation of an elongated trough shaped recess(11) in the first surface (5,52) extending longitudinally from end toend of the main panel member (4,51), the recess (11) defining a base(13) which forms the infill panel (14) and the rail receiving surfaces(15), and the recess (11) defining opposite side walls (17) extendingfrom the base (13) which form respective side edge surfaces (28) of thestiles (12).
 15. A panel as claimed in claim 14 characterised in thatportion (25) of the base (13) of the recess (11) is raised or lowered toform the infill panel (14) of corresponding shape.
 16. A panel asclaimed in claim 13 characterised in that the main veneer sheet (10) isprovided with a longitudinally extending grain pattern (31) whichextends substantially parallel to the stiles (12).
 17. A panel asclaimed in claim 13 characterised in that each rail (16) has first andsecond opposite major surfaces (18,19), the first major surface (18)corresponding to the first surface (2) of the panel (1,50), the secondmajor surface (3) being secured to the corresponding rail receivingsurface (15) of the main panel member (4,51), each rail (16) comprisinga secondary substrate (20) having first and second opposite major faces(21,22) corresponding to the first and second surfaces (18,19) of therail (16), and a secondary veneer sheet (24) laminated to the first face(21) of the secondary substrate (20) for forming the first surface (18)of the rail (16).
 18. A panel as claimed in claim 17 characterised inthat the secondary veneer sheet (24) of each rail (16) is provided witha longitudinally extending grain pattern (32), which extendssubstantially parallel to the rail (16).
 19. A panel as claimed in claim13 characterised in that the main substrate (7) is a one piece substrateformed from a single sheet of material.
 20. A panel as claimed in claim13 characterised in that the main veneer sheet (10) covers the entirefirst face (10) of the main substrate (7).
 21. A panel as claimed inclaim 13 characterised in that the main veneer sheet (10) is formed froma single sheet or veneer.
 22. A panel as claimed in claim 13characterised in that each rail receiving surface (16) is substantiallyco-planar with an adjacent portion (26) of the infill panel surface. 23.A panel as claimed in claim 13 characterised in that the main andsecondary substrates (7,20) may be of similar or different materials,and may be selected from any one or more of the following materials:anysuitable wood or reconstituted wood, softwood, hardwood, chipboard,oriented strand board, high density, medium or low density fibre board,and any composite material, and the main and secondary veneer sheets(10,34) may be similar or different and may be matched or otherwise andmay be selected from any one or more of the following types of veneersheets:timber veneer sheet of hardwood or softwood, synthetic foil,veneer sheet of plastics material which may or may not simulate a grain,decorative veneer sheet, and any other suitable veneer sheet.